Post-to-beam fastener

ABSTRACT

Various embodiments provide a post-to-beam fastener including a head, a tip, and a threaded shank connected to the head at a first end and the tip and a second end. In various embodiments, threaded shank includes a longitudinal axis extending from the head to the tip, and the tip includes a recess operable to removably receive a drill bit to the fastener.

PRIORITY CLAIM

This application is a continuation of and claims priority to and thebenefit of U.S. patent application Ser. No. 16/580,465, filed Sep. 24,2019, which claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 62/834,856, filed Apr. 16, 2019, and claimspriority to and the benefit of U.S. Provisional Patent Application Ser.No. 62/737,046, filed Sep. 26, 2018, the entire contents of each ofwhich are incorporated herein by reference.

BACKGROUND

Generally, known post-to-beam fastening operations use several separateassemblies for enabling the insertion of a bolt into a wood deck postand/or wood deck beam. More specifically, certain known post-to-beamfastening operations start with a ½ inch (1.27 cms) drill bit insertedinto the chuck of a power drill. The power drill and the drill bit froma predrilled hole in the wood and the drill bit is removed from thehole. A ½ inch (1.27 cms) bolt with a washer is hammered into the hole,and a washer and nut are affixed to the opposite end of the bolt. Thenut is tightened until the bolt is locked into place. The ½ inch (1.27cms) diameter bolt can have a carriage head or a hex head. The carriagehead bolt includes a square shoulder that, when hammered into the holein the wood, will lock into place, providing enough torque to facilitatetightening the nut as needed. The hex head bolt enables the user to usea wrench to hold the head of the bolt while another wrench is used totighten the nut. Both hex head bolts and carriage head bolt such asshown in FIGS. 1A and 1B have been utilized in this manner.

There exists a need for an improved post-to-beam fastener and method ofpost-to-beam fastening that are faster and more efficient.

BRIEF SUMMARY

Various embodiments of the present disclosure provide an improvedpost-to-beam fastener and an improved method of post-to-beam fasteningthat are faster and more efficient. These embodiments solve the aboveproblems in part by providing a fastener that combines the pre-drillingand bolt installation steps of post-to-beam fastening into one step(i.e., a single step).

Various embodiments of the present disclosure provide a fastenerincluding a head and a drill tip operable to drill through wood. Athreaded shank connects the head at a first end and the drill tip at asecond end. The threaded shank has a longitudinal axis extending fromthe head to the drill tip. The head includes a retaining featureoperable to removably secure the fastener to a drill to enable forwardand backward movement along the longitudinal axis of the shank.

Various embodiments of the present disclosure provide a fastenerincluding a head and a tip connected by a threaded shank with alongitudinal axis extending from the head to the tip. The tip includes arecess operable to removably receive and facilitate attachment of adrill bit to the tip end of the fastener.

Various embodiments of the present disclosure provide a method offastening in which a fastener is attached to a drill by a retainingfeature operable to removably secure the fastener to the drill andenable forward and backward movement along a longitudinal axis. Thefastener is drilled through a deck post and a deck beam. The fastener isdetached from the drill. A nut is installed and tightened on thefastener to press and connect the deck post and deck beam adjacent toeach other along the longitudinal axis.

Various embodiments of the present disclosure provide a method offastening in which a drill bit is removably attached to a fastener in arecess proximate a tip of the fastener. The drill bit and the fastenerare drilled through a deck post and a deck beam. The drill bit isdetached from the fastener. A nut is installed and tightened on thefastener to press and connect the deck post and deck beam adjacent toeach other along the longitudinal axis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described embodiments of the present disclosure in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein:

FIG. 1A is a side view of a prior art fastener showing a head portionand a shank portion of the fastener;

FIG. 1B is a side view of another prior art fastener showing a headportion and a shank portion of the fastener;

FIG. 2A is a schematic view showing a prior art American Wood Council(AWC) requirement for post-to-beam fastening;

FIG. 2B is a schematic view showing a prior art InternationalResidential Code (IRC) requirement for post-to-beam fastening;

FIG. 3 is a side perspective view of one example embodiment of afastener of the present disclosure, showing a head, a shank, and a tipof the fastener, and showing a fastener driving tool adapter thatengages with the head of the fastener;

FIG. 4 is a side perspective view of another example embodiment of thefastener of the present disclosure, showing a head, a shank, a tip, atip recess, and a drill bit received in the tip recess;

FIG. 5 is a schematic view showing a comparison of a known method ofpost-to-beam fastening for the prior art fasteners of FIGS. 1A and 1B, amethod of post-to-beam fastening for the fastener of FIG. 3 , and amethod of post-to-beam fastening for the fastener of FIG. 4 ;

FIG. 6A is a side perspective view of the fastener of FIG. 3 ;

FIG. 6B is a side perspective view of the fastener of FIG. 4 ;

FIG. 7 is an enlarged fragmentary perspective view of a portion of theshank and tip of the fastener of FIG. 3 ;

FIG. 8A is a side perspective view of another example embodiment of afastener of the present disclosure, showing a head, a shank, and abreakaway tip of the fastener;

FIG. 8B is a side perspective view of the fastener of FIG. 8A shownafter the breakaway tip is separated from the shank of the fastener;

FIG. 9 is a side view of another example embodiment of a fastener of thepresent disclosure, showing a head, a shank, and a tip of the fastener;

FIG. 10A is an enlarged side perspective view of another exampleembodiment of a fastener of the present disclosure, showing a head, ashank, and a breakaway tip of the fastener;

FIG. 10B is a side view of the fastener of FIG. 10A shown after thebreakaway tip is separated from the shank of the fastener;

FIG. 11 is a perspective view of another example embodiment of afastener of the present disclosure, showing a head, a shank, and awinged tip of the fastener;

FIG. 12A is a side view of the fastener driving tool adapter of FIG. 3 ;

FIG. 12B is a fragmentary enlarged front prospective view of the head ofthe fastener of FIG. 3 ;

FIG. 12C is a fragmentary enlarged top prospective view of the head ofthe fastener of FIG. 4 ;

FIG. 13 is a fragmentary enlarged top prospective view of anotherexample embodiment of a head of a fastener of the present disclosure,showing a head, and a head cap extending from the head of the fastener;

FIG. 14A is a perspective view of the fastener of FIG. 13 ;

FIG. 14B is an enlarged perspective view of a fastener driving tool andthe fastener of FIG. 13 , showing the head cap of the fastener connectedto the fastener driving tool;

FIG. 15A is a perspective end view of another example embodiment of afastener of the present disclosure, showing a head, a shank, a tip, anda tip recess of the fastener;

FIG. 15B is a fragmentary enlarged perspective view of the tip and thetip recess of the fastener of FIG. 15A;

FIG. 16A is a perspective view of another example embodiment of afastener of the present disclosure, showing a head, a shank, a tip, athreaded tip recess, and a plurality of drill tips that can be threadedinto the threaded drill tip recess of the fastener;

FIG. 16B is a fragmentary enlarged perspective view of the shank, thetip, the threaded tip recess, and one of the plurality of drill tips ofFIG. 16A;

FIG. 17A is a side view of another example embodiment of a fastener ofthe present disclosure, showing a head, a plurality of ribs on a bottomsurface of the head, a shank, and a tip of the fastener;

FIG. 17B is an enlarged bottom perspective view of the head of thefastener of FIG. 17A;

FIG. 17C is an enlarged top perspective view of the head of the fastenerof FIG. 17A;

FIG. 17D is a side cross-sectional view of the fastener of FIG. 17A;

FIG. 17E is an enlarged fragmentary side view of the head and the partof the shank of the fastener of FIG. 17A;

FIG. 17F is an enlarged fragmentary side view of the plurality of ribson the bottom surface of the head of the fastener of FIG. 17A;

FIG. 18A is a side view of another example embodiment of a fastener ofthe present disclosure and a drill bit of the present disclosureremovably connected to the fastener;

FIG. 18B is a perspective view of the fastener of FIG. 18A;

FIG. 18C is another perspective view of the fastener of FIG. 18A;

FIG. 18D is a side view of the tip of the fastener of FIG. 18A;

FIG. 19A is a side view of another example embodiment of a fastener ofthe present disclosure;

FIG. 19B is a perspective view of the fastener of FIG. 19A;

FIG. 19C is an enlarged fragmentary side view of a rib on the bottomsurface of the head of the fastener of FIG. 19A;

FIG. 19D is an enlarged fragmentary perspective view of an exampleembodiment of the plurality of ribs on the bottom surface of the head ofthe fastener of FIG. 19A; and

FIG. 19E is an enlarged fragmentary perspective view of the plurality ofribs on the bottom surface of the head of another example embodiment ofthe present disclosure.

DETAILED DESCRIPTION

While the devices and methods described herein may be embodied invarious forms, the drawings show and the specification describes certainexemplary and non-limiting embodiments. Not all of the components shownin the drawings and described in the specification may be required, andcertain implementations may include additional, different, or fewercomponents. Variations in the arrangement and type of the components;the shapes, sizes, and materials of the components; and the manners ofconnections of the components may be made without departing from thespirit or scope of the claims. Unless otherwise indicated, anydirections and/or order referred to in the specification reflect theorientations of the components shown in the corresponding drawings anddo not limit the scope of the present disclosure. Further, terms thatrefer to mounting methods, such as mounted, connected, etc., are notintended to be limited to direct mounting methods but should beinterpreted broadly to include indirect and operably mounted, connected,and like mounting methods. This specification is intended to be taken asa whole and interpreted in accordance with the principles of the presentdisclosure and as understood by one of ordinary skill in the art.

FIGS. 1A and 1B illustrate example known hex head fastener 10 and anexample known carriage head fastener 50. The example known hex headfastener 10 includes: (1) a shank 20; and (2) a head 30 integrallyconnected to an end of the shank 20. The example known carriage headfastener 50 includes: (1) a shank 60; and (2) a head 70 integrallyconnected to an end of the shank 60.

Various embodiments of the present disclosure are used for post-to-beamfastening applications. Additionally, these embodiments may be adaptedfor other decking construction processes. When installing a deck post toa deck beam, the International Code Council (ICC) presently requires 2½inch (6.35 cms) pre-drilled through-bolts per connection. FIGS. 2A and2B show the American Wood Council (AWC) and International ResidentialCode (IRC) requirements for post-to-beam fastening.

FIGS. 3, 6A, 7, and 12B illustrate one example embodiment of thepost-to-beam fastener of the present disclosure that is generallyindicated by numeral 100. This illustrated example embodiment showsselected components of the post-to-beam fastener 100, and othercomponents of the post-to-beam fastener 100 not discussed herein will bereadily understood by those skilled in the art.

The illustrated example post-to-beam fastener 100, sometimes referred toas a “1 Piece Fastener Concept,” includes: (1) a head 110; (2) a shank140 integrally connected to the head 110 at a first end 142 of the shank140; and (3) a tip 170 integrally connected to the shank 140 at a secondend 144 of the shank 140. In this illustrated example, the post-to-beamfastener 100 (i.e., the 1 Piece Concept) is configured as a ½ inch (1.27cms) diameter bolt (i.e., fastener 100) with a tip 170 and a head 110opposite of the tip 170. It should be appreciated that while thepost-to-beam fastener 100 is described as a ½ inch (1.27 cms) diameterbolt, any suitable different type of fastener and any suitable differentsize of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head 110 has a hexagonal shape andincludes a retaining feature. More specifically, the head includessurfaces that define: (1) a recess 112 defined in a top surface (notlabeled) of the head 110; and (2) a recess indent 114 defined in atleast one sidewall (not labeled) of the recess 112. In this illustratedexample, the surfaces of the head 110 that define the recess 112 areconfigured to engage with a fastener driving tool adapter 120 duringdriving and/or insertion of the fastener 100 into a workpiece (e.g., thebeam or the post) (not shown). In this illustrated example, the surfacesthat define the recess indent 114 are configured to positively retainthe fastener driving tool adapter 120 in the recess 112 of the fastener100 while a driving tool (not shown) drives the fastener 100 into aworkpiece. As such, the head 110 retains the fastener driving tooladapter 120 within the recess 112 while the fastener 100 is movedaxially forward and backward within the workpiece during driving and/orinsertion of the fastener 100 into the workpiece.

In this illustrated example, the shank 140 includes a plurality ofthread formations 146 extending outwardly from the shank 140 to form athreaded shank that connects to the head 110 at the first end 142 of theshank 140. In this illustrated example, the fastener 100 has the tip 170at the second end 144 of the shank 140, and the shank 140 has alongitudinal axis extending from the head 110 to the tip 170.

In this illustrated example, the tip 170 of the fastener 100 isconfigured as a drill tip, which may be milled or forged. In thisillustrated example, the head 110 includes a feature to positivelyretain the fastener 100 to be moved forward and backward axially. Inthis illustrated example, the head 110, the shank 140, and the drill tipof tip 140 form a unitary structure that enables a user to drill andinstall the fastener 100 in one operation. That is, the fastener 100including the tip 170 (i.e., the drill tip) drills, drives and/orinserts the fastener 100 into the workpiece without having to use aseparate drill bit to first drill or otherwise form a hole through theworkpiece. In this illustrated example, the tip 170 of the fastener 100includes a flute 174 formed in the tip 170 of the fastener 100. In thisillustrated example, the flute 174 is positioned proximate to the end ofthe tip 170; however other positions of the flute 174 are possible inaccordance with the present disclosure. As such, the flute 174 isconfigured to collect wood chips generated by drilling (i.e., thecutting action) of the drill tip on the workpiece (e.g., the deck postand the deck beam). During operation, to improve the efficiency of thedrill tip, wood chips can be removed periodically during drilling,driving and/or insertion of the fastener 100 through the workpiece(e.g., the deck post and the deck beam).

In this illustrated example, removal of the wood chips generated bydrilling through the workpiece and collected in the flute 174, isfacilitated by movement of the fastener 100 forward and backwardaxially. For example, as best seen in FIGS. 3, 6A, and 12B, the head 110of the fastener 100 includes a square shaped recess 112 including therecess indent 114 (or hole) which enables the head to lock an adapterinto the recess 112 of the head 110 (and positively retain thefastener). This permits the fastener 100 to be pulled out of the holebeing generated in the workpiece, clearing out the wood chips collectedfrom the flutes 174 of the tip 170. This method of drilling is known bya person skilled in the art as “peck-drilling.”

FIGS. 6B and 12C illustrate another example embodiment of thepost-to-beam fastener of the present disclosure that is generallyindicated by numeral 200. This illustrated example embodiment of thepost-to-beam fastener 200 is similar to fastener 100, as discussedabove. This illustrated example embodiment shows selected components ofthe post-to-beam fastener 200, and other components of the post-to-beamfastener 200 not discussed herein will be readily understood by thoseskilled in the art.

The illustrated example post-to-beam fastener 200, also referred to as a“1 Piece Fastener Concept,” includes: (1) a head 210; (2) a shank 240integrally connected to the head 210 at a first end 242 of the shank240; and (3) a tip 270 suitably connected to the shank 240 at a secondend 244 of the shank 140. In this illustrated example, the post-to-beamfastener 200 (i.e., the 1 Piece Fastener Concept) is configured as a ½inch (1.27 cms) diameter bolt (i.e., fastener 200) with the tip 270 andthe head 210 opposite of the tip 170. It should be appreciated thatwhile the post-to-beam fastener 100 is described as a ½ inch (1.27 cms)diameter bolt, any suitable different type of fastener and any suitabledifferent size of fastener may be used in accordance with the presentdisclosure.

In this illustrated example, the head 210 is configured as a carriagebolt head and includes a retaining feature. More specifically, the head210 includes surfaces that define: (1) a recess 212 defined in a topsurface (not labeled) of the head 210; and (2) a recess indent 214defined in at least one sidewall (not labeled) of the recess 212. Inthis illustrated example, the surfaces that define the recess 212 areconfigured to engage with the fastener driving tool adapter 120 (shownin FIGS. 3 and 12A) during drilling, driving and/or insertion of thefastener 200 into a workpiece (e.g., the beam or the post) (not shown).In this illustrated example, the surfaces that define the recess indent214 are configured to positively retain the fastener driving tooladapter 120 in the recess 212 of the fastener 200 while a fastenerdriving tool (not shown) drives the fastener 200 into a workpiece. Assuch, the head 210 retains the fastener driving tool adapter 120 withinthe recess 212 while the fastener 200 is moved axially forward andbackward within the workpiece during drilling, driving and/or insertionof the fastener 200 into the workpiece.

In this illustrated example, the shank 140 includes: (1) a squareshoulder 245 adjacent to the first end 242 of the shank 240; and (2) aplurality of thread formations 246 extending outwardly from the shank240 to form a threaded shank that connects to the head 210 at the squareshoulder 245 of the shank 140. In this illustrated example, the fastener200 has a tip 270 at second end 244 of the shank 240, and the shank 240has a longitudinal axis extending from the head 210 to the tip 270.

In this illustrated example, the tip 270 of the fastener 200 isconfigured as a drill tip, which may be milled or forged. In thisillustrated example, the head 210 includes a feature to positivelyretain the fastener 200 to be moved forward and backward axially. Inthis illustrated example, the head 210, the shank 240, and the drill tipof tip 270 form a unitary structure that enables a user to drill andinstall the fastener 200 in one operation. That is, the fastener 200including the tip 270 (i.e., the drill tip) drills, drives and/orinserts the fastener 200 into the workpiece without having to use aseparate drill bit to first drill or otherwise form a hole through theworkpiece. In this illustrated example, the tip 270 of the fastener 200includes a flute 274 formed in the tip 270 of the fastener 200. In thisillustrated example, the flute 274 is positioned proximate to the end ofthe tip 270, however other positions of the flute 274 are possible. Assuch, the flute 274 is configured to collect wood chips generated bydrilling (i.e., the cutting action) of the drill tip on the workpiece(e.g., the deck post and the deck beam). During operation, to improvethe efficiency of the drill tip, wood chips can be removed periodicallyduring drilling, driving and/or insertion of the fastener 200 throughthe workpiece.

In this illustrated example, removal of the wood chips generated bydrilling through the workpiece and collected in the flute 274, isfacilitated by movement of the fastener 200 forward and backwardaxially. For example, as best seen in FIGS. 6B, and 12C the head 210 ofthe fastener 200 includes surfaces that define a square shaped recess212 including the recess indent 214 (or hole) and that lock an adapterinto the recess 212 of the head 210 (i.e., positively retains thefastener). This permits the fastener 200 to be pulled out of the holebeing generated in the workpiece, clearing out the woodchips collectedfrom the flute 274 of the tip 270.

Referring to fasteners associated with the 1 Piece Fastener Concept,several different variations of the drill tip on the end of the fastenerare possible in accordance with the present disclosure. As discussedabove, the drill tip (i.e., drill point) enables the user to drill,drive and/or install the fastener using a singular, complete assemblyincluding a fastener and a drill tip. As such, there is no need for theuser to carry separate drill bits. In various embodiments, the flutes(e.g., drill flutes or cutting flutes) of the drill tip are formed orotherwise defined into the fastener itself. In various embodiments, theflutes of the drill tip are approximately 2 inches (5.08 cms) long.Peck-drilling is typically used with flutes of such a length (e.g., 2inches (5.08 cms) long). However, it will be appreciated that the flutescan vary in size, shape and number flutes that are defined on the tip ofthe fastener. As such, in various other embodiments, longer drill flutescould be used, which may reduce the amount of backward and forwarddrilling (i.e., peck-drilling) used but may require the fastener to belonger overall.

FIGS. 8A, 8B, 9, 10A, 10B, and 11 illustrate several different drill tipand/or flute configurations. In some embodiments, the drill tip may bebroken, or knocked off of the end of the shank of the fastener by ahammer, or other such tool. In some embodiments, the fastener includes abreakaway tip including the drill tip, and at least a portion of theflute. In these embodiments, the breakaway tip is broken off at abreakaway line or breakaway joint. In these embodiments, the breakawaytip is broken off from the fastener at the breakaway line or breakawayjoint after a nut is installed on the fastener and tightened against theworkpiece (e.g., the deck post and/or the deck beam).

In particular, FIGS. 8A and 8B, illustrate selected components ofanother example embodiment of a post-to-beam fastener generallyindicated by numeral 300. Post-to-beam fastener 300 is similar tofastener 100 discussed above and includes a milled drill tip and fluteformed or otherwise defined in the tip of the post-to-beam fastener 300.

The illustrated example post-to-beam fastener 300 includes: (1) a head310; (2) a shank 340 integrally connected to the head 310 at a first end342 of the shank 340; and (3) a tip 380 removably connected to the shank340 at a second end 344 of the shank 340. In this illustrated example,the post-to-beam fastener 300 is configured as a ½ inch (1.27 cms)diameter bolt (i.e., fastener) with the head 310 opposite of the tip380. It should be appreciated that while the post-to-beam fastener 300is described as a ½ inch (1.27 cms) diameter bolt, any suitabledifferent type of fastener and any suitable different size of fastenermay be used in accordance with the present disclosure.

In this illustrated example, the head 310 is configured with a hexagonalshape and includes a retaining feature. More specifically, the head 310includes surfaces that define: (1) a recess (not shown) defined in a topsurface (not labeled) of the head 310; and (2) a recess indent (notshown) defined in at least one sidewall (not labeled) of the recess. Inthis illustrated example, the surfaces that define the recess areconfigured to engage with a fastener driving tool adapter (not shown)during drilling, driving and/or insertion of the fastener 300 into aworkpiece (e.g., the beam or the post) (not shown). In this illustratedexample, the surfaces that define the recess indent are configured topositively retain the fastener driving tool adapter in the recess of thefastener 300 while a fastener driving tool (not shown) drills, drives,and/or inserts the fastener 300 into a workpiece. As such, the head 310retains the fastener driving tool adapter within the recess while thefastener 100 is moved axially forward and backward within the workpieceduring drilling, driving and/or insertion of the fastener 300 into theworkpiece.

In this illustrated example, the shank 340 includes: (1) a plurality ofthread formations 346 extending outwardly from the shank 340 to form athreaded shank that connects to the head 310 at the first end 342 of theshank 340; and (2) a breakaway line or breakaway joint 360 definedbetween the second end 344 of the shank 340 and the tip 380 of thefastener 300. In this illustrated example, the threaded shank (i.e.,shank 340) connects to the head 310 at the first end 342 of the shank340. In this illustrated example, the fastener 300 has a the tip 380 atsecond end 344 of the shank 340, and the shank 340 has a longitudinalaxis extending from the head 310 to the tip 370.

In this illustrated example, the drill tip of tip 380 includes a flute384 formed in the tip 380 of the fastener 300. More specifically, theflute 384 is formed on the tip 380 and positioned between the breakawayline or breakaway joint 360 and the end of the tip 384, however otherpositions of the flute 384 are possible. As such, the flute 384 helps tocollect wood chips generated by drilling (i.e., the cutting action) ofthe drill tip on the workpiece (e.g., the deck post and the deck beam).In this illustrated example, the tip 380 of the fastener 300 isconfigured as a breakaway drill tip, which is removed from the shank 340of the fastener 300 once the drilling, driving, and/or insertion of thefastener 300 is complete. More specifically, the breakaway drill tip oftip 380 enables a user to remove the drill tip from the fastener 300once the hole is drilled through the workpiece and a nut (not shown) isinstalled around the thread formations 346 of the shank 340 and suitablytightened against the workpiece. As such, the fastener 300 including thetip 380 drills, drives and/or inserts the fastener 300 into theworkpiece without having to use a separate drill bit to first drill orotherwise form a hole through the workpiece.

FIGS. 9, 10A, and 10B illustrate selected components of another exampleembodiment of a post-to-beam fastener generally indicated by numeral400. Post-to-beam fastener 400 is similar to fastener 100 discussedabove. Post-to-beam fastener 400 includes a forged drill tip (i.e.,forged drill point). While the forged drill tip is similar to the milleddrill tip and flute discussed above, the process to manufacture forgeddrilling tips is less expensive. In this illustrated example embodiment,an ending diameter of the forged drill tip of the fastener 400 isslightly larger than the ½ inch (1.27 cms) major diameter of threads ofthe fastener 400. The slightly larger ending diameter of the forgeddrill tip produces a hole in the workpiece that is slightly larger thanthe fastener 400. This increased diameter of the hole in the workpiecemakes installation of the fastener 400 easier. In this illustratedexample, the fastener 400 includes a breakaway tip that is removed orotherwise broken off before a nut is suitably installed on the fastenerand suitably tightened against the workpiece because the ending diameterof the forged drill tip is larger than the threads of the fastener 400.In this illustrated example, the breakaway tip (see FIGS. 10A and 10B)is used and knocked off by a hammer or other such tool beforeinstallation of the nut(not shown) onto the fastener 400.

The illustrated example post-to-beam fastener 400 includes: (1) a head410; (2) a shank 440 integrally connected to the head 410 at a first end442 of the shank 440; and (3) a tip 490 suitably connected to the shank440 at a second end 444 of the shank 440. In this illustrated example,the post-to-beam fastener 400 is configured as a ½ inch (1.27 cms)diameter bolt (i.e., fastener 400) with the head 410 opposite of the tip490. It should be appreciated that while the post-to-beam fastener 400is described as a ½ inch (1.27 cms) diameter bolt, any suitabledifferent type of fastener and any suitable different size of fastenermay be used in accordance with the present disclosure.

In this illustrated example, the head 410 is configured with a hexagonalshape and includes a retaining feature. More specifically, the head 410includes surfaces that define: (1) a recess (not shown) defined in a topsurface (not labeled) of the head 410; and (2) a recess indent (notshown) defined in at least one sidewall (not labeled) of the recess. Inthis illustrated example, the surfaces that define the recess areconfigured to engage with a fastener driving tool adapter (not shown)during drilling, driving and/or insertion of the fastener 400 into aworkpiece (e.g., beam or post) (not shown). In this illustrated example,the surfaces that define the recess indent are configured to positivelyretain the fastener driving tool adapter in the recess of the fastener400 while a fastener driving tool (not shown) drills, drives and/orinserts the fastener 400 into a workpiece. As such, the head 410 retainsthe fastener driving tool adapter within the recess while the fastener400 is moved axially forward and backward within the workpiece duringdrilling, driving and/or insertion of the fastener 400 into theworkpiece.

In this illustrated example, the shank 440 includes: (1) a plurality ofthread formations 446 extending outwardly from the shank 440 to form athreaded shank that connects to the head 410 at the first end 442 of theshank 340; and (2) a breakaway line or breakaway joint 460 disposedbetween the second end 444 of the shank 440 and the tip 490 of thefastener 400. In this illustrated example, the threaded shank (i.e.,shank 440) connects to the head 410 at the first end 442 of the shank440. In this illustrated example, the fastener 400 forms the tip 490 atsecond end 444 of the shank 440, and the shank 440 has a longitudinalaxis extending from the head 410 to the tip 490.

In this illustrated example, the tip 490 includes: (1) a first outerdiameter 492 at a first end of the tip 490 adjacent to the breakawayline or breakaway joint 460; and (2) a second outer diameter 494 at asecond end of the tip 490 opposite the first end. In this illustratedexample, the second outer diameter 494 of the tip 490 is slightly largerthan the major diameter of the thread formations 446 of the shank 440.As such, the tip 490 of the fastener 400 produces a hole in theworkpiece that is slightly larger than the major diameter of the threadformations 446 of the shank 440. In this illustrated example, the tip490 of the fastener 400 is configured as a breakaway drill tip, which isremoved from the shank 440 of the fastener 400 once a hole is drilledthrough the workpiece. As such, the fastener 400 including the tip 490,drills a hole into the workpiece without having to use a separate drillbit to drill or otherwise form a hole through the workpiece. In thisillustrated example, once the hole is drilled through the workpiece, thetip 490 is removed from the fastener 400 at the breakaway line orbreakaway joint 460 such that a nut (not shown) is suitably installedaround the thread formations 446 of the shank 440 and suitably tightenedagainst the workpiece.

FIG. 11 illustrates selected components of an additional exampleembodiment of a post-to-beam fastener generally indicated by numeral600. The post-to-beam fastener 600 is similar to fastener 100 discussedabove and includes a winged drill tip (i.e., winged cutting tip) formedor otherwise defined in the tip of the post-to-beam fastener 600. Inthis illustrated example embodiment, the winged drill tip of thefastener 600 is used to cut, drill, or otherwise form a proper holediameter in a workpiece for the installation of the fastener 600. Incertain embodiments, the winged cutting tip of the fastener 600 is abreakaway tip. In certain other embodiments, only the wings of thewinged cutting tip breakaway from the fastener. For example, the wingsbreak off of the winged cutting tip when a specialized nut is installedon the fastener and suitably tightened against the deck post and deckbeam.

The illustrated example post-to-beam fastener 600 includes: (1) a head610; (2) a shank 640 integrally connected to the head 610 at a first end642 of the shank 640; and (3) a tip 670 suitably connected to the shank640 at a second end 644 of the shank 640. In this illustrated example,the post-to-beam fastener 600 is configured as ½ inch (1.27 cms)diameter bolt (i.e., fastener 600) with the head 610 opposite of the tip670. It should be appreciated that while the post-to-beam fastener 600is described as a ½ inch (1.27 cms) diameter bolt, any suitabledifferent type of fastener and any suitable different size of fastenermay be used in accordance with the present disclosure.

In this illustrated example, the head 610 is configured with a hexagonalshape and includes a retaining feature. More specifically, the head 610includes surfaces that define: (1) a recess (not shown) defined in a topsurface (not labeled) of the head 610; and (2) a recess indent (notshown) defined in at least one sidewall (not labeled) of the recess. Inthis illustrated example, the surfaces that define the recess areconfigured to engage with a fastener driving tool adapter (not shown)during drilling, driving and/or insertion of the fastener 600 into aworkpiece (e.g., beam or post) (not shown). In this illustrated example,the surfaces that define the recess indent are configured to positivelyretain the fastener driving tool adapter in the recess of the fastener600 while a fastener driving tool (not shown) drills, drives and/orinserts the fastener 600 into a workpiece. As such, the head 610 retainsthe fastener driving tool adapter within the recess while the fastener600 is moved axially forward and backward within the workpiece duringdrilling, driving and/or insertion of the fastener 600.

In this illustrated example, the shank 640 includes: (1) a plurality ofthread formations 646 extending outwardly from the shank 640 to form athreaded shank that connects to the head 610 at the first end 642 of theshank 640; and (2) a breakaway line breakaway joint 660 disposed betweenthe second end 644 of the shank 640 and the tip 670 of the fastener 400.In this illustrated example, the threaded shank (i.e., shank 640)connects to the head 610 at the first end 642 of the shank 640. In thisillustrated example, the fastener 600 has the tip 670 at second end 644of the shank 640, and the shank 640 has a longitudinal axis extendingfrom the head 610 to the tip 670.

In this illustrated example, the drill tip of the tip 670 includes: (1)a first wing formation 674 a extending radially from an outer surface ofthe tip 670; and (2) a second wing formation 674 b extending radiallyfrom the outer surface of the tip 670. In this illustrated example, thefirst and second wing formations 674 a and 674 b define a wing formationdiameter that is slightly larger than an outer diameter of the tip 670.In this illustrated example, the wing formation diameter of the firstand second wing formations 674 a and 674 b is slightly larger than themajor diameter of the thread formations 646 of the shank 640. As such,the tip 670 and the first and second wing formations 674 a and 674 b ofthe fastener 600 produce a hole in the workpiece that is slightly largerthan the than the major diameter of the thread formations 646 of theshank 640. In this illustrated example, the tip 670 of the fastener 600is configured as a breakaway drill tip, which is removed from the shank640 of the fastener 600 once a hole is drilled through the workpiece. Assuch, the fastener 600 including the tip 670, drills a hole into theworkpiece without having to use a separate drill bit to drill orotherwise form a hole through the workpiece. In this illustratedexample, once the hole is drilled through the workpiece, the tip 670including the first and second wing formations 674 a and 674 b isremoved from the fastener 600 at the breakaway line or breakaway joint660 such that a nut (not shown) is suitably installed around the threadformations 646 of the shank 640 and suitably tightened against theworkpiece.

In one example embodiment, only the wings break away from the tip of thefastener. More specifically, the first and second wing formations areconfigured to break away or otherwise be removed from the tip of thefastener following the drilling of the hole in the workpiece. Forexample, the wings break off when a specialized nut is installed on thebolt and tightened against the deck post and deck beam. As such, the nutis configured to break off or otherwise remove the first and second wingformations as the nut is suitably installed on the fastener and suitablytightened against the workpiece. As such, in this example embodiment,the tip remains suitably connected to the fastener following thedrilling, driving, and/or insertion of the fastener into the workpiece.

FIGS. 4, 13A, and 13B illustrate another example embodiment of thepost-to-beam fastener of the present disclosure that is generallyindicated by numeral 1100. This illustrated example embodiment showsselected components of the post-to-beam fastener 1100, and othercomponents of the post-to-beam fastener 1100 not discussed herein willbe readily understood by those skilled in the art.

The illustrated example post-to-beam fastener 1100, includes: (1) a head1110; (2) a shank 1140 integrally connected to the head 1110 at a firstend 1142 of the shank 1140; (3) a tip 1170 integrally connected to theshank 1140 at a second end 1144 of the shank 140; and (4) a drill bit1180 removably attached to the tip 1170 of the fastener 1100. In thisillustrated embodiment, the post-to-beam fastener 1100 is referred to asa “2 Piece Fastener Concept.” that includes a ½ inch (1.27 cms) diameterbolt (i.e., fastener 1100) with a recess in an end (i.e., the tip 1170)of the bolt to removably attach the drill bit 1180. During operation,the drill bit 1180 is attached to the tip 1170 of the post-to-beamfastener 1100 and the user drills a hole through a workpiece (e.g., thedeck post and the deck beam). After drilling is complete, the drill bit1170 is removed from the fastener 1100. In this illustrated example,utilizing a drill bit produces efficient drilling and/or cutting actionof the 2 Piece Fastener Concept. It should be appreciated that while thepost-to-beam fastener 1100 is described as a ½ inch (1.27 cms) diameterbolt, any suitable different type of fastener and any suitable differentsize of fastener may be used in accordance with the present disclosure.

In various embodiments of the 2 Piece Fastener Concept, known drill bitsare used. For example, in one such embodiment a drill bit with a hexshank can be received in a hex recess of the end of the fastener (e.g.,a ¼ inch (0.635 cms) hex recess accommodating a ¼ inch (0.635 cms) hexshank spade bit). In another such embodiment, customized drill bits arecreated to optimize attachment to the recess in the end of the fastener.By utilizing drill bits, efficient cutting action can be achieved withthe 2 Piece Fastener Concept.

In various embodiments, combining the predrilling and installationaccording to the present disclosure, the 2 Piece Fastener Conceptprovides a faster user experience. During operation, the 2 PieceFastener Concept operation begins with connecting the bolt (i.e.,fastener) to the drill driver. This can be done using a socket, star, orsquare drive adapter. Next, a drill bit is inserted into the recess onthe tip end of the fastener. The recess at the end of the fastenerenables the user to install various common drill bits. The drill bit isused to drill the fastener through the workpiece (e.g., the deck postand/or the deck beam). Once the cutting operation has been completed,the drill bit can be removed from the other side of the post (and usedwith subsequent 2 Piece Fastener Concept fasteners, or any otheroperation). A washer and nut are installed and tightened.

In this illustrated example, the head 1110 is configured with ahexagonal shape and includes a retaining feature. More specifically, thehead 1110 includes surfaces that define: (1) a recess (not shown)defined in a top surface (not labeled) of the head 1110; and (2) arecess indent (not shown) defined in at least one sidewall (not shown)of the recess. In this illustrated example, the surface that define therecess are configured to engage with a fastener driving tool adapter(not shown) during drilling, driving and/or insertion of the fastener1100 into a workpiece (e.g., the beam or the post) (not shown). In thisillustrated example, the surfaces that define the recess indent areconfigured to positively retain the fastener driving tool adapter in therecess of the fastener 1100 while a driving tool (not shown) drives thefastener 1100 into a workpiece. As such, the head 1110 retains thefastener driving tool adapter within the recess while the fastener 1100is moved axially forward and backward within the workpiece duringdriving and/or insertion of the fastener 100 into the workpiece.

In this illustrated example, the shank 1140 includes a plurality ofthread formations 1146 extending outwardly from the shank 1140 to form athreaded shank that connects to the head 1110 at the first end 1142 ofthe shank 1140. In this illustrated example, the threaded shank (i.e.,shank 1140) connects to the head 1110 at the first end 1142 of the shank1140. In this illustrated example, the fastener 1100 forms the tip 1170at second end 1144 of the shank 1140, and the shank 1140 has alongitudinal axis extending from the head 610 to the tip 670.

In this illustrated example, the tip 1170 of the fastener 1100 includessurfaces that define a recess 1176 in the tip 1170 to removably attachthe drill bit 1180 to the fastener 1100. As best seen in FIGS. 13A and13B, the recess 1176 is configured as a hex recess (e.g., a ¼ inch(0.635 cms) hex recess) that accepts any standard hex shank drill bits(e.g., ¼ inch (0.635 cms) hex shank drill bits) In this illustratedexample embodiment, the recess 1176 does not provide any positiveengagement of the drill bit 1180. That is, there is nothing securing(i.e., locking) the drill bit 1180 in place within the recess 1176,besides the force from the operator while drilling. As such, in thisillustrated example, the drill bit 1180 is easily removed from therecess 1176 of the fastener 1100 after drilling and/or cutting a holethrough a workpiece.

In another example embodiment, the recess of the fastener includes anadditional positive retaining feature (not shown) (e.g., similar to theindent described in FIG. 12B with respect to the head 110 of the 1 PieceFastener Concept fastener 100) to removably secure the drill bit in theend of the fastener. As such, the positive retaining feature secures thedrill bit in place within the recess, along with the force from theoperator while drilling.

FIGS. 16A and 16B illustrate another example embodiment of thepost-to-beam fastener of the present disclosure that is generallyindicated by numeral 1200. The post-to-beam fastener 1200 is similar tofastener 1100, discussed above. This illustrated example embodimentshows selected components of the post-to-beam fastener 1100, and othercomponents of the post-to-beam fastener 1100 not discussed herein willbe readily understood by those skilled in the art.

The illustrated example post-to-beam fastener 1200, includes: (1) a head1210; (2) a shank 1240 integrally connected to the head 1210 at a firstend 1242 of the shank 1240; (3) a tip 1270 integrally connected to theshank 1240 at a second end 1244 of the shank 1240; and (4) a drill bit1280 a removably attached to the tip 1270 of the fastener 1200. In thisillustrated embodiment, the post-to-beam fastener 1200 is referred to asa “2 Piece Fastener Concept.” that includes a ½ inch (1.27 cms) diameterbolt (i.e., fastener 1200) with a recess in an end (i.e., the tip 1270)of the fastener to removably attach the drill bit to the fastener.During operation, the drill bit 1280 is attached to the tip 1270 of thepost-to-beam fastener 1200 and the user drills a hole through aworkpiece (e.g., the deck post and the deck beam). After drilling iscomplete, the drill bit 1280 a is removed from the fastener 1200. Inthis illustrated example, utilizing a drill bit produces efficientdrilling and/or cutting action of the 2 Piece Fastener Concept fastener.It should be appreciated that while the post-to-beam fastener 1200 isdescribed as a ½ inch (1.27 cms) diameter bolt, any suitable differenttype of fastener and any suitable different size of fastener may be usedin accordance with the present disclosure.

In this illustrated example, the head 1210 is configured with ahexagonal shape and includes a retaining feature. More specifically, thehead 1210 includes surfaces that define: (1) a recess (not shown)defined in a top surface (not labeled) of the head 1210; and (2) arecess indent (not shown) defined in at least one sidewall (not shown)of the recess. In this illustrated example, the surfaces that define therecess are configured to engage with a fastener driving tool adapter(not shown) during drilling, driving and/or insertion of the fastener1200 into a workpiece (e.g., the beam or the post) (not shown). In thisillustrated example, the surfaces that define the recess indent areconfigured to positively retain the fastener driving tool adapter in therecess of the fastener 1200 while a driving tool (not shown) drives thefastener 1200 into a workpiece. As such, the head 1210 retains thefastener driving tool adapter within the recess while the fastener 1200is moved axially forward and backward within the workpiece duringdrilling, driving and/or insertion of the fastener 1200 into theworkpiece.

In this illustrated example, the shank 1240 includes a plurality ofthread formations 1246 extending outwardly from the shank 1240 to form athreaded shank that connects to the head 1210 at the first end 1242 ofthe shank 1240. In this illustrated example, the threaded shank (i.e.,shank 1240) connects to the head 1210 at the first end 1242 of the shank1240. In this illustrated example, the fastener 1200 forms the tip 1270at second end 1244 of the shank 1240, and the shank 1240 has alongitudinal axis extending from the head 1210 to the tip 1270.

In this illustrated example, the tip 1270 of the fastener 1200 includessurfaces that define a threaded recess 1276 in the tip 1270 to removablyattach to one of a plurality of different drill bits such as drill bits1280 a, 1280 b, or 1280 c. For example, as best seen in FIGS. 16A and16B, the threaded recess 1276 includes an internal thread formation (notlabeled) (e.g., a ¼-20 internal thread) extending from a surface of thethreaded recess 1276 of the tip 1270 of the fastener 1200. In thisexample embodiment, the internal thread formation is configured to mateor otherwise accept a drill bit having a complimentary external threadformation (e.g., external ¼-20 threads). In this example embodiment, thethreaded recess 1276 including the internal thread formation has anadvantage in that the threads of the threaded recess 1276 positivelyengage the threads of the drill bit so it stays locked into place whiledrilling. Once the operation is finished, the drill bit is unscrewed andreused.

In various embodiments, users (such as contractors or deck builders)prefer carriage bolts that have a low-profile head compared to hex boltsor other such bolts. The low-profile head of carriage bolts may beperceived to look cleaner and more professional than hex bolts byhomeowners (customers of the deck builders). Carriage bolts have nosharp edges that may interfere with homeowners using the deck.

Known carriage bolts have a square shoulder that locks the bolt into thewood when driven with a hammer. To attach a nut to the bolt at the endof the post-to-beam fastening process, the bolt must be rotatably heldin place by the wood. In some instances, however, the square shoulderreams a hole in the wood, allowing the bolt to rotate freely. Then, thebolt cannot be rotatably held in place by the wood, thus removing theability to fasten the connection with a nut.

FIGS. 17A to 17F illustrate another example embodiment of thepost-to-beam fastener of the present disclosure that is generallyindicated by numeral 1300. In this illustrated example embodiment, thepost-to-beam fastener 1300 is a bolt (i.e., fastener 1300) for use inthe 2 Piece Fastener Concept for post-to-beam fastening. Morespecifically, the fastener 1300 is a carriage bolt with a locking ribpattern replacing the square shoulder. The locking rib pattern,consisting of a plurality of ribs extending radially from the shank tothe edge of the head, resists rotation and rotatably holds the fastener1300 in place by engagement with the workpiece (e.g., the deck postand/or the deck beam). Each of the plurality of ribs is angled such thatthe fastener 1300 can spin freely in a clockwise direction but dig inwhen the fastener 1300 tries to rotate counterclockwise. Tightening anut onto the fastener 1300 after drilling through the workpiece inducesa counterclockwise rotation in the fastener, so if the ribs prevent thisrotation, the fastener can be tightened fully.

The illustrated example post-to-beam fastener 1300 includes: (1) a head1310; (2) a shank 1340 integrally connected to the head 1310 at a firstend 1342 of the shank 1340; (3) a tip 1370 integrally connected to theshank 1340 at a second end 1344 of the shank 1340; and (4) a drill bit(not shown) removably attached to the tip 1370 of the fastener 1300.

In this illustrated example, the head 1310 is configured as a carriagebolt head and includes a retaining feature. More specifically, the head1310 includes surfaces that define: (1) a recess 1312 defined in a topsurface (not labeled) of the head 1310; and (2) a locking rib pattern1316 including a plurality of ribs 1318 extending outwardly from abottom surface (not labeled) of the head 1310. In this illustratedexample, the surfaces that define the recess 1312 are configured toengage with a fastener driving tool adapter (not shown) during drilling,driving and/or insertion of the fastener 1300 into a workpiece (e.g.,the beam or the post) (not shown). In this illustrated example, theplurality of ribs 1318 of the rib locking pattern 1316 engages with theworkpiece such that the fastener 1300 does not freely spin when a nut(not shown) is suitably tightened around the fastener 1300. It should beappreciated that while recess 1312 is shown as a star-shaped recess,other recesses may be used, such as a socket recess (engageable by asocket), and a square recess (engageable by a square drive adapter).

In this illustrated example, each rib 1318 of the locking rib pattern1316 includes a leading face 1318 a and a trailing face 1318 b that meetat an apex 1318 c of the rib 1318. The leading face 1318 a forms anangle (not labeled) with respect to the bottom surface of the head 1310.Similarly, the trailing face 1318 b forms an angle (not labeled) withrespect to the bottom surface of the head 1310. In this illustratedexample embodiment, the angle formed between the leading face 1318 a andthe bottom surface of the head 1310 is greater than the angle formedbetween the trailing face 1318 b and the bottom surface of the head1310. As such the leading face 1318 a is at a sharper angle with respectto the workpiece (not shown), and the trailing face 1318 b is at ashallower angle with respect to the workpiece.

In this illustrated example, the shank 1340 includes a plurality ofthread formations 1346 extending outwardly from the shank 1340 to form athreaded shank that connects to the head 1310 at the first end 1342 ofthe shank 1340.

In this illustrated example, the thread formations 1346 of the shank1340 are configured such that tightening a nut onto the fastener 1300induces a counter-clockwise rotation of the fastener 1300, and looseningthe nut from the fastener 1300 induces a clockwise rotation of thefastener 1300. As such, when the nut is tightened onto the threadformations 1346, the fastener 1300 is tightened against the workpiece,causing the locking rib pattern 1316 to come into contact with theworkpiece. When the nut is loosened from the thread formations 1346, thefastener 1300 is loosened or backed away from the workpiece, causing thelocking rib pattern 1316 to come out of contact with the workpiece.

In this illustrated example, as the nut is tightened onto the threadformations 1346, the tightening of the nut induces a counter-clockwiserotation of the fastener 1300, and the apex 1318 c and leading edges1318 a of the ribs 1318 come into contact with the workpiece, Thus, thesharper angle of the leading edges 1318 a contact the workpiece duringthe tightening process, creating a rotational resistance with respect tothe workpiece by “biting” into the surface of the workpiece. As such,the interaction between the ribs 1318 and the workpiece prevent thefastener from spinning while the nut is being tightened. Conversely,when the nut is loosened from the thread formations 1346, the looseningof the nut induces a clockwise rotation of the fastener, and the apex1318 c and leading edges 1318 a of the ribs 1318 come out of contactwith the workpiece. Thus the shallower angle of the trailing edges 1318b reduce the rotational resistance with respect to the workpiece toallow the fastener 1300 to spin freely.

In this illustrated example, the tip 1370 of the fastener 1300 includessurfaces that define a recess 1376 in the tip 1370 to removably attachthe drill bit (not shown) to the fastener 1300. In this illustratedexample embodiment, the recess 1376 is configured as a hex recess (e.g.,a ¼ inch (0.635 cms) hex recess) that accepts any standard hex shankdrill bits (e.g., ¼ inch (0.635 cms) hex shank drill bits). In thisillustrated example embodiment, the recess 1376 does not provide anypositive engagement of the drill bit. That is, there is nothing securing(i.e., locking) the drill bit in place within the recess 1376, besidesthe force from the operator while drilling. As such, in this illustratedexample, the drill bit is easily removed from the recess 1376 of thefastener 1300 after drilling and/or cutting a hole through a workpiece.

In this example embodiment, as illustrated in FIGS. 17A and 17E, awasher 1320 is integrated with the head 1310 of the fastener 1300. Anintegrated washer further reduces the number of pieces that users haveto handle during installation (though some users may not presently usewashers with known carriage bolts). The integrated washer also increasesthe bearing surface area of the head of the fastener. A larger bearingsurface may provider a tighter post-to-beam connection, resulting inpeace of mind for users and their customers. In this illustrated exampleembodiment, the head 1310 of the fastener 1300 has a diameter similar toa standard fender washer. Other diameters between a known carriage boltand standard fender washer, or greater than the standard fender washer,are also possible.

FIGS. 18A, 18B, 18C, and 18D illustrate another example embodiment ofthe post-to-beam fastener of the present disclosure that is generallyindicated by numeral 1400. The post-to-beam fastener 1400 is similar tofastener 1100, discussed above. This illustrated example embodimentshows selected components of the post-to-beam fastener 1400, and othercomponents of the post-to-beam fastener 1400 not discussed herein willbe readily understood by those skilled in the art.

The illustrated example post-to-beam fastener 1400, includes: (1) a head1410; (2) a shank 1440 integrally connected to the head 1410 at a firstend 1442 of the shank 1440; (3) a tip 1470 integrally connected to theshank 1440 at a second end 1444 of the shank 1440; and (4) a drill bit1480 removably attached to the tip 1470 of the fastener 1400. In thisillustrated embodiment, the post-to-beam fastener 1400 is referred to asa “2 Piece Fastener Concept.” that includes a ½ inch (1.27 cms) diameterbolt (i.e., fastener 1200) with a recess in an end (i.e., the tip 1470)of the fastener to removably attach the drill bit to the fastener.During operation, the drill bit 1480 is attached to the tip 1470 of thepost-to-beam fastener 1400 and the user drills a hole through aworkpiece (e.g., the deck post and the deck beam). After drilling iscomplete, the drill bit 1480 is removed from the fastener 1400. In thisillustrated example, utilizing a drill bit produces efficient drillingand/or cutting action of the 2 Piece Fastener Concept fastener. Itshould be appreciated that while the post-to-beam fastener 1400 isdescribed as a ½ inch (1.27 cms) diameter bolt, any suitable differenttype of fastener and any suitable different size of fastener may be usedin accordance with the present disclosure.

In this illustrated example, the head 1410 is configured with ahexagonal shape and includes a retaining feature. More specifically, thehead 1410 includes surfaces that define: (1) a recess (not shown)defined in a top surface (not labeled) of the head 1410; (2) a recessindent (not shown) defined in at least one sidewall (not shown) of therecess; and (3) a washer 1420 is integrated with the head 1410 of thefastener 1400. In this illustrated example, the surfaces that define therecess are configured to engage with a fastener driving tool adapter(not shown) during drilling, driving and/or insertion of the fastener1400 into a workpiece (e.g., the beam or the post) (not shown). In thisillustrated example, the surfaces that define the recess indent areconfigured to positively retain the fastener driving tool adapter in therecess of the fastener 1400 while a driving tool (not shown) drives thefastener 1400 into a workpiece. As such, the head 1410 retains thefastener driving tool adapter within the recess while the fastener 1400is moved axially forward and backward within the workpiece duringdrilling, driving and/or insertion of the fastener 1400 into theworkpiece.

In this illustrated example, the tip 1470 includes: (1) a plurality ofthread formations 1446 extending outwardly from at least a portion ofthe tip 1470; and (2) one or more v-grooves 1448 defined in and by thethread formations 1446. In this illustrated example, the shank (i.e.,shank 1440) connects to the head 1410 at the first end 1442 of the shank1440. In this illustrated example, the fastener 1400 forms the tip 1470connected to the second end 1444 of the shank 1440, and the shank 1440has a longitudinal axis extending from the head 1410 to the tip 1470. Asclearly shown in FIGS. 18A, 18B, and 18C, in this illustrated exampleembodiment, the shank 1440 does not include any thread formations andthat the tip 1470 includes the thread formations. In this illustratedexample embodiment, as clearly shown in FIGS. 18A, 18B, and 18C, theshank 1440 is approximately three times longer than the tip 1470.

In this illustrated example, the one or more v-grooves 1448 defined inthe thread formations 1446 extend along a portion of the threadformations 1446 (e.g., ¾ of an inch (1.905 cms) of the thread formations1446). In this illustrated example, the one or more v-grooves 1448 causea reduction of the friction generated by the cutting action of thethread formations 1446 into the workpiece during drilling, driving,and/or insertion of the fastener 1400 into the workpiece.

In this illustrated example, the tip 1470 of the fastener 1400 includessurfaces that define a recess 1476 in the tip 1470 to removably attachto the drill bit 1480. As best seen in FIGS. 18A and 18B, the recess1476 is configured as a hex recess (e.g., a ¼ inch (0.635 cms) hexrecess) that accepts any standard hex shank drill bits (e.g., ¼ inch(0.635 cms) hex shank drill bits). In this illustrated exampleembodiment, the recess 1476 does not provide any positive engagement ofthe drill bit 1480. That is, there is nothing securing the drill bit1480 in place within the recess 1476, besides the force from theoperator while drilling. As such, in this illustrated example, the drillbit 1480 is easily removed from the recess 1476 of the fastener 1400after drilling and/or cutting a hole through a workpiece.

FIGS. 19A, 19B, 19C, 19D, and 19E illustrate various alternative furtherexample embodiments of the post-to-beam fastener of the presentdisclosure that are generally indicated by numeral 1500. Thepost-to-beam fastener 1500 shown in FIGS. 19A, 19B, 19C, and 19D issimilar to fastener 1100, discussed above. This illustrated exampleembodiment shows selected components of the post-to-beam fastener 1500,and other components of the post-to-beam fastener 1500 not discussedherein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener 1500 includes: (1) a head1510; (2) a shank 1540 integrally connected to the head 1510 at a firstend 1542 of the shank 1540; (3) a tip 1570 integrally connected to theshank 1540 at a second end 1544 of the shank 1540; and (4) a drill bit(not shown) removably attached to the tip 1570 of the fastener 1500.

In this illustrated example, the head 1510 is configured with ahexagonal shape and includes: (1) a washer 1520 integrated with the head1510 of the fastener 1500; and (2) a locking rib pattern 1516 includinga plurality of ribs 1518 extending outwardly from a bottom surface (notlabeled) of the washer 1520 integrated with the head 1510.

In one example, the washer 1520 is configured as a standard washerhaving a diameter of substantially 1.06 inches (2.6924 cms). In anotherexample, the washer (not shown) is configured as a larger fender-typewasher having a diameter of substantially 1.375 inches (3.4925 cms). Itshould be appreciated that while two washers having different dimensionsare discussed, other suitable integrated washers having other suitabledimensions may be used in accordance with the present disclosure.

In this illustrated example, each rib 1518 of the locking rib pattern1516 includes a leading face 1518 a and a trailing face 1518 b that meetat an apex 1518 c of the rib 1518. The leading face 1518 a forms anangle (not labeled) with respect to the bottom surface of the washer1520 integrated with the head 1510. Similarly, the trailing face 1518 bforms an angle (not labeled) with respect to the bottom surface of thewasher 1520 integrated with the head 1510. In this illustrated exampleembodiment, the angle formed between the leading face 1518 a and thebottom surface of the washer 1520 is greater than the angle formedbetween the trailing face 1518 b and the bottom surface of the washer1520. As such the leading face 1518 a is at a sharper angle with respectto the workpiece (not shown), and the trailing face 1518 b is at ashallower angle with respect to the workpiece.

In one illustrated example, best seen in FIGS. 19B and 19D, theplurality of ribs 1518 of rib pattern 1516 include partial ribsconfigured to radially extend from a location along the outercircumference of the washer 1520 to an interior location spaced aspecified distance from the shank 1540. As such, the ribs 1516 radiallyextend along the surface of the washer 1520 a partial distance betweenthe outer circumference of the washer and the shank 1540.

In this illustrated example, the shank 1540 includes: (1) a plurality ofthread formations 1546 extending outwardly from at least a portion ofthe shank 1540 to form a threaded shank that connects to the head 1510at the first end 1542 of the shank 1540; and (2) one or more v-grooves1548 defined in the thread formations 1546. In this illustrated example,the threaded shank (i.e., shank 1540) connects to the head 1510 at thefirst end 1542 of the shank 1540. In this illustrated example, thefastener 1500 forms the tip 1570 at second end 1544 of the shank 1540,and the shank 1540 has a longitudinal axis extending from the head 1510to the tip 1570.

In this illustrated example, the one or more v-grooves 1548 defined inthe thread formations 1546 extend along a portion of the threadformations 1546 (e.g., ¾ of an inch of the thread formations 1546). Inthis illustrated example, the one or more v-grooves 1548 cause areduction of the friction generated by the cutting action of the threadformations 1546 into the workpiece during drilling, driving, and/orinsertion of the fastener 1500 into the workpiece.

In this illustrated example, the tip 1570 of the fastener 1500 includessurfaces that define a recess 1576 in the tip 1570 to removably attachto a drill bit (not shown). As best seen in FIG. 19B, the recess 1576 isconfigured as a hex recess (e.g., a ¼ inch (0.635 cms) hex recess) thataccepts any standard hex shank drill bits (e.g., ¼ inch (0.635 cms) hexshank drill bits). In this illustrated example embodiment, the recess1576 does not provide any positive engagement of the drill bit. That is,there is nothing securing the drill bit in place within the recess 1576,besides the force from the operator while drilling. As such, in thisillustrated example, the drill bit is easily removed from the recess1576 of the fastener 1500 after drilling and/or cutting a hole through aworkpiece.

In another illustrated example, best seen in FIG. 19E, the fastener 1600includes a plurality of ribs 1618 of rib pattern 1616 that include fullribs configured to radially extend from a location along the outercircumference of the washer 1620 to an interior location adjacent to theshank 1640. As such, the ribs 1618 radially extend along the surface ofthe washer 1620 the entire distance between the outer circumference ofthe washer 1620 and the shank 1640.

In various embodiments, of the 1 Piece Fastener Concept, severalvariations of the feature (e.g., the recess in the head) to positivelyretain the bolt to be moved forward and backward axially are possible.As the drill tip drives into the wood workpiece, small wood chips arecreated within the hole. For the drill to operate efficiently, thesechips should be cleared to allow for more chips to be created. If thesechips are not cleared the drill tip will get clogged with chips, thusimpeding advancement of the drill tip and heating the drill tip due toexcessive friction. A positive engagement head clears the wood chips byallowing the bolt to be pulled back and forth out of the hole.

In one such embodiment, FIGS. 12A and 12B illustrate a ¼ inch (0.635cms) Hex to ¼ inch (0.635 cms) Square Adapter. This adapter includes aball detent which locks into the indent (or hole) defined surfaces ofthe square recess defined in surfaces of the head of the bolt. As such,the positive engagement provided by the ¼ inch (0.635 cm) Hex to ¼ inch(0.635 cms) Square Adapter enables the bolt to be pulled back and forthout of the hole to clear the wood chips generated while drilling thehole.

In another such embodiment, FIGS. 13, 14A, and 14B illustrate anintegrated driving tool adapter integrated with the head of the boltallowing for direct attachment of the integrated driving tool adapter tothe drill chuck. This direct attachment is a form of positiveengagement, as the drill chuck locks into the integrated driving tooladapter. As such, the positive engagement provided by the integrateddriving tool adapter enables the bolt to be pulled back and forth out ofthe hole to clear the wood chips generated while drilling the hole.

In various embodiments of the 2 Piece Fastener Concept, the recess atthe end of the bolt enables the user to install various common drillbits for use in the post-to-beam fastener installation methods of thepresent disclosure. The drill bit is inserted into the end of the boltand used to drill the bolt through the post. Once the cutting operationhas been completed, the drill bit can be removed (and used withsubsequent 2 Piece Concept bolts, or any other operation).

FIG. 5 illustrates a comparison between methods of post-to-beamfastening using known methods (the “Current Solution”), the 1 PieceFastener Concept of the present disclosure, and the 2 Piece FastenerConcept of the present disclosure. The known method begins with a drillbit attached to the drill driver. A ½ inch hole is pre-drilled throughthe post, and a ½ inch (1.27 cms) through bolt is hammered into thehole. A washer and nut are attached and tightened.

By combining the predrilling and installation according to the presentdisclosure, the 1 Piece Fastener Concept and the 2 Piece FastenerConcept provide a faster user experience. The 1 Piece Fastener Conceptoperation begins with positively retaining the bolt (i.e., at the squarerecess with hole in the head) to the drill driver. Next, the bolt isdrilled and driven through the wood using the peck-drilling techniquedescribed above. Once the bolt is driven all the way through the post,the drill driver is removed from the head of the bolt. A washer and nutare assembled on the end of the bolt, and the entire assembly isfastened tightly together.

The 2 Piece Fastener Concept operation begins with connecting the boltto the drill driver. This can be done using a socket, star, or squaredrive adapter. Next, a 6 inch (15.24 cms) long drill bit is insertedinto the recess on the tip end of the bolt. The bolt is drilled anddriven into the post in one motion without the peck-drilling used by the1 Piece Concept operation. The drill bit is then removed from the otherside of the post, and a washer and nut are installed and tightened.

Thus, the several aforementioned objects and advantages are mosteffectively attained. The 1 Piece Fastener Concept and 2 Piece FastenerConcept of the present disclosure combine pre-drilling and boltinstallation steps of post-to-beam fastening into one step. Use of thebolts and methods of the present disclosure result in faster and moreefficient installations of deck posts and deck beams.

Various changes and modifications to the present embodiments describedherein will be apparent to those skilled in the art. Such changes andmodifications can be made without departing from the spirit and scope ofthe present subject matter and without diminishing its intendedadvantages. It is therefore intended that such changes and modificationsbe covered by the appended claims.

1. A fastener assembly comprising: a drill bit including a hexagonalshaped first end and an opposite second end having a tip; and a fastenerincluding: a head; a threaded shank section including exterior threadedformations and interior surfaces defining a hexagonal shaped recessconfigured to removably receive the hexagonal shaped first end of thedrill bit, wherein the interior surfaces are configured to engage thehexagonal shaped first end of the drill bit, wherein the interiorsurfaces enable the hexagonal shaped first end of the drill bit to beremoved from the hexagonal shaped recess; and a non-threaded shanksection connected to the head at a first end and to the threaded shanksection at a second end, the non-threaded shank section having alongitudinal axis extending from the head to the threaded shank section,the non-threaded shank section including a first portion closest to thehead that does not include any thread formations and a second portionclosest to the threaded shank section that does not include any threadformations, wherein the first portion of the non-threaded shank sectionand the second portion of the non-threaded shank section areapproximately three times longer than the threaded shank section,wherein the drill bit has a length that is longer than the non-threadedshank section and that is longer than the threaded shank section,wherein the head, the threaded shank section, and the non-threaded shanksection are integrally formed.
 2. The fastener assembly of claim 1,wherein the head has a hexagonal shape.
 3. The fastener assembly ofclaim 1, wherein the head defines a recess.
 4. The fastener assembly ofclaim 1, which includes a washer integrally connected to a bottomportion of the head.
 5. The fastener assembly of claim 1, which includesa washer positionable adjacent to a bottom portion of the head.
 6. Thefastener assembly of claim 1, which includes locking ribs under thehead.
 7. The fastener assembly of claim 6, wherein each of the lockingribs extends radially outwardly.
 8. The fastener assembly of claim 1,wherein the length of the drill bit is approximately as long as thenon-threaded shank section and the threaded shank section combined.
 9. Afastener assembly comprising: a drill bit including a hexagonal shapedfirst end and an opposite second end having a tip; and a fastenerincluding: a head, and a shank having a free end and an end connected tothe head, the free end including interior surfaces defining a hexagonalshaped recess configured to removably receive the hexagonal shaped firstend of the drill bit, wherein the interior surfaces are configured toengage the hexagonal shaped first end of the drill bit, wherein theinterior surfaces enable the hexagonal shaped first end of the drill bitto be removed from the hexagonal shaped recess, the shank including anexterior threaded formation that extends from the free end of the shankto the end of the shank connected to the head; wherein the drill bit hasa length that is longer than one-half of a length of exterior threadedformation, wherein the head and the shank are integrally formed.
 10. Thefastener assembly of claim 9, wherein the head has a hexagonal shape.11. The fastener assembly of claim 9, wherein the head defines a recess.12. The fastener assembly of claim 9, which includes a washer integrallyconnected to a bottom portion of the head.
 13. The fastener assembly ofclaim 9, which includes a washer positionable adjacent to a bottomportion of the head.
 14. The fastener assembly of claim 9, whichincludes locking ribs under the head.
 15. The fastener assembly of claim14, wherein each of the locking ribs extends radially outwardly.
 16. Thefastener assembly of claim 9, wherein the length of the drill bit isapproximately as long as the exterior threaded formation.
 17. A fastenerassembly comprising: a drill bit including a hexagonal shaped first endand an opposite second end having a tip; and a fastener including: ahead, and a shank having a free end and an end connected to the head,the free end including interior surfaces defining a hexagonal shapedrecess configured to removably receive the hexagonal shaped first end ofthe drill bit, wherein the interior surfaces are configured to engagethe hexagonal shaped first end of the drill bit, wherein the interiorsurfaces enable the hexagonal shaped first end of the drill bit to beremoved from the hexagonal shaped recess, the shank including anexterior threaded formation that extends along a portion of the shankfrom the free end of the shank to the end of the shank connected to thehead; wherein the drill bit has a length that is longer than one-half ofa length of the shank, wherein the head and the shank are integrallyformed.
 18. The fastener assembly of claim 17, wherein the head has ahexagonal shape.
 19. The fastener assembly of claim 17, wherein the headdefines a recess.
 20. The fastener assembly of claim 17, which includesa washer integrally connected to a bottom portion of the head.